Dr G V K PRASAD, EP-OPERATIONS&

HIS TEAM

EXECUTIVE CHAIRMAN

HYDEL POWER 8.25 MWHYDEL POWER 8.25 MW WIND POWER 3.25 MWWIND POWER 3.25 MW

SOLAR POWER 1.15 MWSOLAR POWER 1.15 MW

SUGAR PLANTSUGAR PLANT

HEAVY ENGINEERING UNITHEAVY ENGINEERING UNITHOTELHOTEL

CAPTIVE POWER - 18 MW CAPTIVE POWER - 18 MW

CEMENT : 5.32 MTPA CEMENT : 5.32 MTPA

KCP CEMENTPRODUCTION CAPACITY

Location Capacity

Macherla,AP 0.80 MTPA

R K PURAM-AP- L-1 1.86 MTPA

R K PURAM-AP – L-2 1.66 MTPA

Nellore Grinding Unit

(Under execution)1.00 MTPA

TOTAL 5.32 MTPA

4

KCP CEMENT BUSINESS KCP CEMENT BUSINESS

BUILDING THE NATION SINCE 1958

THE KCP LIMITED

Process

Flows

Process

Flows

Limestone Mining

Crushing

Raw Milling

Pyro Processing

Clinker Cooling

Cement Grinding

Packing & Dispatch

Coal Milling

Transport

Diesel

for loaders, dozers

and compressors

Diesel for dumpers and trucks

Electrical Energy

for crushers

Electrical Energy for

Mill drive and fans

Heat Energy from

kiln off gases

Heat Energy from

fuel input

Electrical Energy

for fans, drive and

clinker breaker

Electrical Energy for

Mill drive and fans

LateriteLaterite

Gypsum

Pre calcinationHeat Energy from

fuel input

Electrical Energy forKiln

drive, fans

Electrical Energy

for mill drive and fans

Heat Energy from

fuel input/waste heat

from clinker cooler

✓ Energy flows✓ Energy flows

• Energy consumption

nearly 40-45% of

production costs

• Mill drives, fans and

conveying systems are

major energy

consumers

• Energy consumption

nearly 40-45% of

production costs

• Mill drives, fans and

conveying systems are

major energy

consumers

Sl No SECTIONCAPACITY- TPH & PERFORMANCE

DESIGN ACHIEVED % CAPACITY

1 CRUSHER 850 1100 129

2 RAW MILL 320 360 113

3 COAL MILL 40 63 158

4 KILN- TPD 4000 5000 125

5CEMENT

MILLS 2X115 2X140 122

TOTAL 44.23 43.93 43.32ALL EQUIPMENTS ARE RUNNING MORE THAN THEIR RATED CAPACITY DUE TO: 1. Continuous improvement in each section2. Process optimization3. Continuous monitoring on performance of core equipments

Sl No SECTIONYEAR

2015-16 2016-17 2017-18

1 CRUSHER 1.16 1.18 1.14

2 RAW MILL 20.43 20.25 19.51

3 COAL MILL 2.29 2.18 2.03

4 KILN 18.49 18.54 18.97

5 UTILITIES 1.87 1.78 1.67

TOTAL 44.23 43.93 43.32

SPECIFIC HEAT 697 690 689REDUCTION OF POWER CONSUMPTION IS MAINLY DUE TO: 1. Modifications carried out in Raw Mill & Coal Mill Sections2. Operation of all Equipment in Fuzzy3. Power consumption Increased in Kiln section is due to operation of kiln at 125% capacity

Sl No YEAR

SPECIFIC ENERGY CONSUMPTIONREDUCTION OVER PREVIOUS

YEAR

Electrical

KWh/T CementThermal - Kcal/Kg

Electrical

LKWh

1 2015-16 69.86 697 (-) 17.40

2 2016-17 68.70 690 (-) 14.60

3 2017-18 67.63 689 (-) 16.31

2018-19 (Target)

65.11 670 (-) 46.87

REDUCTION OF POWER CONSUMPTION IS MAINLY DUE TO: 1. Modifications carried out in Raw Mill & Coal Mill Sections2. Operation of all Equipment in Fuzzy3. Power consumption Increased in Kiln section is due to increased kiln output.

Description National

Benchmark

International

Benchmark

KCP Status

2017-18

Specific Thermal,

K Cal/ Kg.Clinker 676 663 689

Specific Electrical Energy

Consumption,

KWH/ T.Clinker

43.90 44.89 43.32

Specific Electrical Energy

Consumption,

KWH/ T.Cement

63.90 65.00 67.63

1. National Benchmark – CII & CMA Benchmarking - Indian Cement Industries 2018

2. International Benchmark - Whitehopleman Benchmarking 2007-08

KCP ENERGY POLICY

ENERGY ROAD MAP

2015-16• Thermal Energy: 697

kcal/kg.clinker

• Electrical Energy: Clinkerisation- 44.23kwh/T.ClinkerCement- 69.86kwh/T.Cement

2016-17• Thermal Energy: 690

kcal/kg.clinker

• Electrical Energy: Clinkerisation- 43.93kwh/T.ClinkerCement- 68.7kwh/T.Cement

2017-18• Thermal Energy: 689

kcal/kg.clinker

• Electrical Energy: Clinkerisation- 43.32kwh/T.ClinkerCement- 67.63 Kwh/T.Cement

KCP ENERGY ROADMAP

THE KCP LIMITED

S.No For Thermal Energy Reduction

1 Retrofitting of Cooler 1st Grate with latest technology cooler

2 Enhancement of raiser duct area in Pre-Heat Cyclones

3 Installation of high efficiency cooler plates in 1st / 2nd grate of Cooler

4 Minimization of radiation loss by using latest refractory materials

Ultimate Goals:

670 Kcal/Kg Clinker (Thermal Energy) 65.11 KWh/T Cement (Electrical Energy)

S.No For Electrical Energy Reduction

1 Installation of VRM / Roller Press for OPC Grinding

2 Replacement of low efficiency Compressors with high efficiency compressors

with VFD facility

EnMS Implementation Results: ZIMALCO

Implementation Period (yyyy-yyyy) 2016

Total Number of projects 162 projects

Monetary savings in Rs Lakhs

Energy savings in KWh

Rs 589

130.88 LKwh

Total investment made in Rs Lakhs 203.52

Payback time period in Months < 6 months

GHG Emission Reduction (ton CO2) 2645 tons for 3 years

www.ncpc.co.za

ISO 50001- 2011

IMPLEMENTATION RESULTS

EnMS helped Our organization to realize untapped energy

efficiency potential

Designation Roles & Responsibilities

• Drive the energy saving culture in the Smt V L INDIRA DUTT Managing Director

Dr G V K PRASAD Plant Head

Managing Director

organization.

• Set targets for reduction in various parameters inline with the Vision

& Power policy. • Fiscal validation of Power saving projects

and necessary financial allocation.

• Review status of Power saving projects

Department HeadsEnergy Manager

Plant Head through Monthly review meetings.

• Drive employee involvement initiinitiatives.

• Identification & implementation of energy conservation projects.

• Drive employee involvement

OFFICERData Collection

Department HeadsEnergy Manager

initiatives.

• Generate energy conservation ideas. • Measure, Monitor & analyze section

wise energy consumption in the factory

Data Analysis OFFICER

FORMATION OF ENERGY MANAGEMENT CELL

Ideas from visiting other industries

Suggestion from Employees

Suggestion from external audits

New ENCON technologies

Separate Budget Allocation- ENCON

Performance monitoring for 3 months Register successful project

Failure analysis

Audit for successful project after every year

T

O

P

M

A

N

A

G

E

M

E

N

T

Management of energy conservation programs

INPUTS

Project Shortlist Action Plan

Group Execution

Testing

KCP ISO 50001:2011 CERTIFICATE

• Certified during the year 2016 by DNV-GL

Energy Performance (including utilities)

S No Description Units 2016-17 2017-18

1 MTOE reduction MTOE

2 Kiln Thermal SEC kCal/kg cli 690 689

3 Specific Electrical Energy – clinkering kWh/T of clinker 43.93 43.32

4 Specific Electrical Energy – Grinding kWh/T of cement 68.7 67.63

5 CPP Heat rate kCal/kWh 3224 3225

6 CPP auxiliary consumption % 7.92 8.06

7 Thermal Substitution Rate % 7.95 5.73

8 Clinker factor % 1.55 1.55

9 Blended cement (%) of total cement % 34.82 37.05

10 Renewable Energy (RPO) MWH 79818.24 99145.40

11 REC Purchased – Solar REC 189 2975

12 REC Purchased – Non Solar REC 3591 3056

13 Specific CO2 emission Kg CO2/ kg cement738 756

KCP ENERGY PERFORMANCE

THE KCP LIMITED

Energy Saving Projects Implemented in FY 2017-2018

S.No Energy Saving Project Energy

Savings,

Rs.Lakhs

/Annum

Investmen

t Made,

Rs.Lakhs

Pay

Back,

Months

1 Installed MV VFD for Raw Mill Fan in placed for

GRR49.0 41.5 10

2 Retrofit of Raw Mill Fan with high efficiency

impeller

19.6 40 25

3 Installed Airtron Energy savers of 3 Star split

AC Units for 5 No's in a phased manner

1.6 0.25 2

4 Replaced 150W HPSV lamp with 70W LED 50

Fixtures for Street Light for

1.0 1.8 23

5 Replaced of 28W T5 lamp with 18 W LED Tube

for Colony Qtrs for 60 Fixtures

0.1 0.2 20

THE KCP LIMITED

Energy Saving Projects Implemented in FY 2017-2018

S.No Energy Saving Project Energy

Savings,

Rs.Lakhs

/Annum

Investme

nt Made,

Rs.Lakhs

Pay Back,

Months

6 Replaced of 4x14W T5 lamp with 36 W LED

Panel Light for Load centre & Office 0.2 0.9 57

7 Removed 3 nos of Shell cooling fan for kiln

tyre

14.1 0 0

8 Compressed Air line separation for cement

Mills 1 and 2

1.4 0 0

9 Removed air dryer from coal mill circuit 1.1 0 0

10 Nose ring fan speed optimised due to

modification of out let ducting

1.4 0 0

11 Removed damper for Coal Mill Fan and

reduced the damper losses

1.0 0 0

INNOVATIVE PROJECTS2017-18

Innovative ProjectINNOVATIVE PROJECT - 1

Modifications in Raw Mill Fan

Mill PRODUCTION INCREASED BY 8 TPH AND POWER REDUCED BY 65 – 75 KWh

Parameters Units Before After

Mill Feed TPH 355 363

Static

Pressure

mmWC 870 840

Flow M3/hr 487738 511935

Power Kw 1607 1537

Mill Fan

Speed

Rpm 940 920

Raw Mill

Efficiency

% 78.10 80.29

RESULTRESULTRETROFIT OF FAN IMPELLER MODIFICATION IN FAN INLET

BEFORE AFTER

• Power saving achieved : 45 KWh.• Net Power saving achieved : 3,56,400 KWh/Year

PINNOVATIVE PROJECT - 2

OPTIMIZATION OF TYRE COOLING FANS

TWO COOLING FAN SYSTEM SINGLE COOLING FAN SYSTEM

Mill PRODUCTION INCREASED BY 3 TPH AND POWER REDUCED BY 68 KWh

Parameters Units Before After

Mill Feed TPH 64 67

DP across

BF

mmWC 190 90

Mill Fan

Speed

Rpm 880 700

Fan Power KWh 328 260

RESULTRESULT

Before: Homopolymer After: Micro porous Fibers

INNOVATIVE PROJECT – 3PLACEMENT OF COAL MILL BAG FILTER BAGS

After replacement of bags,

Carbon Black usage has

increased from 3.2% to 8.5%

6mm hole(modified) 3mm hole(original)

INNOVATIVE PROJECT – 4 PURGING PIPE HOLE SIZE INCREASE FROM 3 mm TO 6 mm

IN ALL BAG FILTERS

RESULTS ACHIEVED

Bag house DP reduced from 160 mmwg to 110 mmwg

2nd compressor running hrsreduced from 9 hr/day to 2 Hrs /day

After above

modification, power

consumption of Aux

Bag Filters has

reduced by 102 KWh

ZERO INVESTMENT

TEAM WORK IN ENCON

❖

PROJECT

IMPLEMENTED

BY WORKERS

❖ Easy to

operate

❖ Cost

effective

❖ Saving

manpower

PROJECT IMPLEMENTED BY WORKMEN

DEDUSTING STATION FOR EMPLOYEES & WORKMEN

To meet OSHA Standards,KCP installed this Blower togive safe and effective tool fordeducting and clean down oftheir Employees work wearand PPE equipment❖THIS BLOWER PRODUCES

WHICH POSES NO THREAT TO

PERSONAL SAFETY

❖LOWER NOSE EMISSIONS (< 78dB)

❖LOW POWER CONSUMPTION MEETING OSHA STANDARDS

MEETING OSHA STANDARDS

PAT CYCLE-2

Year

Gate to Gate Specific

Energy Consumption

(kcal/kg of equivalent Cement)

Gate to Gate Specific

Energy Consumption

(toe/Tonne of equivalent Cement)

BASE LINE

metric tonne of oil

equivalent (TOE) perunit of product

2014 - 15 1205.05 0.1205

0.11352015 - 16 882.68 0.0883

2016 - 17 910.82 0.0911

2017 - 18 968.10 0.0968

1. Target fixed by PAT Cement sector scheme - 2 for target year 2018 – 19: 0.1135

toe/tonne of equivalent of cement.

2. Status of TOE for the your 2017-2018: 15% lower than Base Line

1. Target fixed by PAT Cement sector scheme - 2 for target year 2018 – 19: 0.1135

toe/tonne of equivalent of cement.

2. Status of TOE for the your 2017-2018: 15% lower than Base Line

Renewable Energy

RENEWABLE ENERGY

Location Green Power Capacity

Cement Unit-II Solar 1.15 MW

Cement Unit-I WHR 2.30 MW

Nekarikallu Hydel 8.25 MW

Uthummalai,

TNWind 3.25 MW

Purchase

(proposed)Solar 5.00 MW

Total 19.95 MW

KCP RENEWABLE ENERGY

USAGE

KCP RENEWABLE ENERGY

USAGE

1st CAPTIVE SOLAR POWER PLANT IN INDIA 1st CAPTIVE SOLAR POWER PLANT IN INDIA

SOLAR WATER HEATER

TOTAL TOWNSHIP AND GUEST HOUSES COVERED WITH SOLAR WATER HEATERS

SOLAR STREET LIGHT

After

BEFORE AFTER

WE WORK TOGETHER AS PARTNERS